U.S. patent application number 12/021661 was filed with the patent office on 2008-07-31 for flake cereal or chip and method for making same.
This patent application is currently assigned to Golden Temple of Oregon, LLC. Invention is credited to Guru Hari Singh Khalsa, Peter Hynding Mattson, Larry Donald Schopf, Bryan Jarel Streety.
Application Number | 20080181991 12/021661 |
Document ID | / |
Family ID | 39668288 |
Filed Date | 2008-07-31 |
United States Patent
Application |
20080181991 |
Kind Code |
A1 |
Schopf; Larry Donald ; et
al. |
July 31, 2008 |
FLAKE CEREAL OR CHIP AND METHOD FOR MAKING SAME
Abstract
Embodiments of the present invention provide a flake having a
high level of whole grains, such as oat groats, nuts and/or other
particulate. An embodiment of the present invention provides a
flake having a low degree of degradation giving the flake a granola
appearance and texture, a relatively large thickness of the flake,
which further contributes to the appearance and the crunchy
texture, and/or uses a low degree of cook to the binding
constituent that provides the high viscosity for binding and a
resultant crunchy texture.
Inventors: |
Schopf; Larry Donald;
(Madison, WI) ; Streety; Bryan Jarel; (Salem,
OR) ; Khalsa; Guru Hari Singh; (Eugene, OR) ;
Mattson; Peter Hynding; (Hillsborough, CA) |
Correspondence
Address: |
SCHWABE, WILLIAMSON & WYATT, P.C.;PACWEST CENTER, SUITE 1900
1211 SW FIFTH AVENUE
PORTLAND
OR
97204
US
|
Assignee: |
Golden Temple of Oregon,
LLC
Eugene
OR
|
Family ID: |
39668288 |
Appl. No.: |
12/021661 |
Filed: |
January 29, 2008 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60887113 |
Jan 29, 2007 |
|
|
|
Current U.S.
Class: |
426/96 ; 426/621;
426/625 |
Current CPC
Class: |
A23L 7/135 20160801;
A23L 5/00 20160801; A23L 7/122 20160801; A23L 7/126 20160801; A23L
29/30 20160801; A23P 30/20 20160801; A23L 7/00 20160801; A23L 21/00
20160801 |
Class at
Publication: |
426/96 ; 426/625;
426/621 |
International
Class: |
A23L 1/164 20060101
A23L001/164; A23L 1/09 20060101 A23L001/09 |
Claims
1. A flake, comprising: approximately 15-70% whole grains, by
weight of the flake; and approximately 10-20% binder, by weight of
the flake, wherein said flake is approximately 0.030 to 0.080 inch
thick.
2. The flake of claim 1, wherein said whole grains comprise
approximately 40-60% by weight of the flake.
3. The flake of claim 1, wherein said whole grains comprise at
least one of oats, wheat, bran, corn, rice, and barley.
4. The flake of claim 1, further comprising approximately 1-10%
nuts, by weight of the flake.
5. The flake of claim 1, wherein said binder comprises at least one
of rice flour and wheat flour.
6. The flake of claim 1, further comprising approximately 20-30% of
a sugar or sweetener, by weight of the flake.
7. The flake of claim 1, further comprising approximately 0.2%
salt, by weight of the flake.
8. The flake of claim 1, further comprising approximately 1-3%
honey, by weight of the flake.
9. The flake of claim 1, further comprising approximately 2-6% oil,
by weight of the flake.
10. The flake of claim 1, wherein said flake comprises a breakfast
cereal.
11. The flake of claim 1, wherein said flake comprises a snack
chip.
12. The flake of claim 1, wherein said flake has a bowl life of
10-15 minutes or more.
13. The flake of claim 1, wherein said flake is approximately 0.040
to 0.070 inch thick.
14. The flake of claim 1, wherein said flake is approximately 0.2
to 2.0 inches in diameter.
15. The flake of claim 1, wherein said flake has a moisture content
of approximately 5% or more.
16. The flake of claim 1, wherein said flake has a moisture content
of approximately 5% or less.
17. A method for producing a flake, comprising: introducing whole
grain particulate and a binder into an extruder in the form of a
blend or blending the whole grain particulate and the binder in the
extruder; cooking the blend to gelatinize the binder to form an
extrudate; cutting the extrudate into pellets and feeding the
pellets into flaking rolls to form flakes approximately 0.030 to
0.080 inch thick; and toasting and drying the flakes.
18. The method of claim 17, wherein said introducing whole grain
particulate and a binder into an extruder comprises introducing
whole grain particulate and a binder into a low shear twin screw
extruder.
19. The method of claim 17, further comprising introducing
additional ingredients into the extruder along with or separate
from the whole grain particulate and the binder, said additional
ingredients being one or more of nuts, sugar/sweetener, honey,
salt, and flavoring.
20. The method of claim 17, wherein the particulate in the blend
comprises approximately 15-70% or more on a dry weight basis of the
extrudate.
21. The method of claim 17, wherein said cutting the extrudate into
pellets and feeding the pellets into flaking rolls comprises
cutting the extrudate into pellets and feeding the pellets into
flaking rolls to form approximately 0.040 to 0.070 inch thick
flakes.
22. The method of claim 17, wherein said toasting and drying is
performed at temperatures of 350-500.degree. F. for approximately 1
to 5 minutes.
23. The method of claim 17, wherein said toasting and drying is
continued until the flakes comprise moisture levels of
approximately 5% or more.
24. The method of claim 17, wherein said toasting and drying is
continued until the flakes comprise moisture levels approximately
5% or less.
25. The method of claim 17, further comprising coating the dried
flakes with at least one of a sugar/sweetener, flavoring, and
oil.
26. The method of claim 17, further comprising, prior to blending
said whole grain particulate with said binder, heat treating said
whole grain particulate for approximately 1 to 60 minutes at a
temperature from approximately 100.degree. F. to approximately
500.degree. F.
27. The method of claim 17, further comprising, prior to blending
said whole grain particulate with said binder, cooking said binder
to form a pregelatinized binder.
28. The method of claim 17, wherein the blend is cooked so that the
binder is cooked to a suitable cook level to gelatinize the binder,
said suitable cook level being one that utilizes an energy input of
approximately 0.030-0.075 horsepower per pound of the binder per
hour with an extrudate moisture content of approximately
25-40%.
29. The method of claim 17, wherein the blend is cooked so that the
binder is cooked to a suitable cook level to gelatinize the binder,
said suitable cook level being one that utilizes an energy input of
approximately 0.015 or more horsepower per pound of the binder per
hour with an extrudate moisture content of approximately
25-40%.
30. A granola flake, comprising: approximately 40-60% by weight oat
groats; approximately 10-20% by weight rice flour; approximately
1-10% by weight pecans; approximately 20-30% by weight evaporated
cane juice; approximately 2-6% canola oil; approximately 0-3%
honey; approximately 0-0.5% vanilla flavoring; and approximately
0-0.2% salt.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims priority to U.S. Provisional
Patent Application No. 60/887,113, filed Jan. 29, 2007, entitled
"Granola Flake Cereal or Chip and Method for Making Same," the
entire disclosure of which is hereby incorporated by reference in
its entirety.
TECHNICAL FIELD
[0002] Embodiments of the present invention relate to the field of
food products and food processing, and, more specifically, to a
flake cereal or snack chip and a method for making the same.
BACKGROUND
[0003] Breakfast cereals utilize many different types of grains as
well as other ingredients and utilize many different forms
including shredded, puffed, flaked, toasted and granular particles.
These forms may be found in hot cereals, dry cereals, granola
cereals and others.
[0004] One primary goal in developing a new cereal product is to
produce a product that is desirable to consumers. Desirability of a
product may be based on factors such as taste, texture, color, and
particle shape/size. Another factor of importance is the ability to
maintain particle integrity when the particle is re-hydrated, for
example when milk is added to the cereal.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] Embodiments of the present invention will be readily
understood by the following detailed description in conjunction
with the accompanying drawings. Embodiments of the invention are
illustrated by way of example and not by way of limitation in the
figures of the accompanying drawings.
[0006] FIG. 1 is a flowchart of an exemplary method of producing a
flake in accordance with various embodiments of the present
invention.
DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION
[0007] In the following detailed description, reference is made to
the accompanying drawings which form a part hereof, and in which
are shown by way of illustration embodiments in which the invention
may be practiced. It is to be understood that other embodiments may
be utilized and structural or logical changes may be made without
departing from the scope of the present invention. Therefore, the
following detailed description is not to be taken in a limiting
sense, and the scope of embodiments in accordance with the present
invention is defined by the appended claims and their
equivalents.
[0008] Various operations may be described as multiple discrete
operations in turn, in a manner that may be helpful in
understanding embodiments of the present invention; however, the
order of description should not be construed to imply that these
operations are order dependent.
[0009] The description may use perspective-based descriptions such
as up/down, back/front, and top/bottom. Such descriptions are
merely used to facilitate the discussion and are not intended to
restrict the application of embodiments of the present
invention.
[0010] The terms "coupled" and "connected," along with their
derivatives, may be used. It should be understood that these terms
are not intended as synonyms for each other. Rather, in particular
embodiments, "connected" may be used to indicate that two or more
elements are in direct physical or electrical contact with each
other. "Coupled" may mean that two or more elements are in direct
physical or electrical contact. However, "coupled" may also mean
that two or more elements are not in direct contact with each
other, but yet still cooperate or interact with each other.
[0011] For the purposes of the description, a phrase in the form
"A/B" or in the form "A and/or B" means (A), (B), or (A and B). For
the purposes of the description, a phrase in the form "at least one
of A, B, and C" means (A), (B), (C), (A and B), (A and C), (B and
C), or (A, B and C). For the purposes of the description, a phrase
in the form "(A)B" means (B) or (AB) that is, A is an optional
element.
[0012] The description may use the phrases "in an embodiment," or
"in embodiments," which may each refer to one or more of the same
or different embodiments. Furthermore, the terms "comprising,"
"including," "having," and the like, as used with respect to
embodiments of the present invention, are synonymous.
[0013] In various embodiments of the present invention, methods,
apparatuses, and systems for producing a flake cereal or snack chip
are provided.
[0014] In an embodiment, methods, apparatuses, and systems for
producing a granola flake cereal or snack chip are provided. For
the purposes of the present invention, the term "granola flake"
refers to a food product in the form of a relatively thick flake,
such as approximately 0.030-0.080 inch thick, having the texture
and appearance of conventional granola, whether in the form of a
breakfast cereal or a snack chip.
[0015] An embodiment of the present invention provides a granola
flake having a high level of whole oat groats, nuts and/or other
particulate. An embodiment of the present invention provides a
flake having a low degree of degradation giving the flake the
"granola" appearance and texture. An embodiment provides a high
thickness of the flakes, which further contributes to the "granola"
appearance and the crunchy texture. An embodiment provides a
relatively low degree of cook to the binding constituent that
provides the high viscosity for binding and a resultant crunchy
texture. Cereal flakes (or snack chips) other than granola flakes
may be made in accordance with embodiments of the present invention
by changing the ingredients utilized.
[0016] A flake in accordance with an embodiment of the present
invention maintains its integrity and texture through processing
and when liquid, such as milk, is introduced for consumption. An
embodiment provides a very crunchy texture and long bowl life of
the finished flakes in milk. For the purposes of the present
invention, the term "bowl life" refers to the length of time the
flake maintains substantial integrity when combined in a bowl with
a liquid, such as milk. In addition, such a flake maintains its
particle integrity during packaging and shipping.
[0017] An embodiment of the present invention provides a flaked,
ready-to-eat breakfast cereal with the appearance, texture and
flavor of granola. Due to the characteristics of the flake, an
embodiment of the present invention may also be provided as a snack
chip. For the purposes of the present invention, the term "granola"
generally refers to a food product consisting of a mixture of
grains, nuts, and/or other ingredients, such as honey, fruit, etc.
Such a mixture is generally baked until crispy.
[0018] Embodiments of the present invention produce a flake that is
thicker than normal cereal flakes and with visual, integral,
undegraded whole grain particulate in the flake to give it a
granola appearance. In an embodiment, the resulting flake also
achieves the desirable extended bowl life of 3-5 times that of
traditional cereal flakes. These results may be accomplished by a
low cook level of the binder in the presence of the particulate
that has experienced a low level of attrition in the process to
form a flake thicker than traditional cereal flakes. In comparison
to traditional cereal flake processes, a flake made of the binder
without the particulate and at the low degree of cook and the
greater thickness would be very hard and crunchy. In accordance
with an embodiment of the invention, the presence of the
particulate in this low cooked, thick flake weakens and interferes
with the crystal structure of the binder sufficiently to soften the
texture of the flake to the desired texture and bowl life.
Alternatively, if the binder were cooked to the higher level of
traditional flakes, the crystal structure of the binder would be
weaker and the binder may not hold the particulate in the flake
sufficiently and the flake with the particulate would have a softer
texture and shorter bowl life than traditional cereals. Further, in
embodiments, the use of various binders, sweeteners, nuts,
pregelatinized starch, etc. and/or the level of particulate affect
the degree of energy input necessary to create the desired crystal
structure, appearance and flake strength.
[0019] An embodiment of the present invention uses oat groats
(hulled oats) or other whole grains (oats (in other forms), wheat,
bran, corn, rice, barley, etc.) or nuts (pecans, almonds, walnuts,
cashews, etc.) in combination with a binder of rice flour/starch,
wheat flour/gluten or other starch or protein source. In an
embodiment, other ingredients may be added to the mixture including
sugar (such as in the form of granulated sugar, raw sugar, brown
sugar, evaporated cane juice) or an artificial sweetener, salt
(such as sea salt), honey, oil (such as canola oil, vegetable oil,
or cottonseed oil), fruit/berries (for example, pieces of dried
fruit or berries), raisins, seeds, flavorings (such as vanilla
flavor), or spices (such as cinnamon), etc.
[0020] In an embodiment, a method of preparing a flake is provided
utilizing a cook level that provides sufficient binding of the
whole grains and a texture crispier and crunchier than conventional
cereal flakes. In an embodiment, a suitable cook level may be one
that utilizes an energy input of 0.015 horsepower or more, such as
approximately 0.030-0.075 horsepower, per pound of binder per hour
at an extrudate moisture content of approximately 25-40%. In
embodiments, the energy may be imparted by mechanical and/or
thermal energy. In an embodiment, the oat groats or other whole
grains (singularly or in combination) may be heat treated (kilned),
and may, in an embodiment, be treated with a preservative (such as
natural tocopherols) to provide suitable flavor and shelf stability
of a ready-to-eat cereal. In an embodiment, an oat groat or other
whole grain that is not heat treated may be used, however, in such
an embodiment, it may be beneficial to treat the finished product
(or an intermediate product thereof) with a preservative and/or
package the final product sufficiently to preserve freshness. The
texture of a finished flake in accordance with an embodiment of the
invention is such that when served in milk as a standard
ready-to-eat breakfast cereal, the flakes have a bowl life (i.e.,
retain their crisp texture) of 10-15 minutes or more, or 3-4 times
longer than conventional flaked cereals.
[0021] An embodiment of the present invention as shown in FIG. 1
provides a process for producing a granola flake. In an embodiment,
a whole grain particulate (such as oat groats) may be heat treated
102 and blended 106 with a binder 104. In an embodiment, the whole
grains may be heat treated for a period of approximately 1-60
minutes, such as approximately 25 minutes, at a temperature of
100-500.degree. F., such as approximately 250.degree. F. In an
embodiment, the blended ingredients may be fed into an extruder
108, such as a low shear twin screw extruder, or other low shear
extruder.
[0022] In embodiments, the particulate may be blended with the
binder 104 before being introduced into extruder 108, or the
ingredients may be separately introduced into extruder 108 and then
blended in extruder 108.
[0023] In embodiments, all or part of the binder may be used in a
pregelatinized form of rice flour, corn flour, wheat flour, or
other starch resulting in an increase in production rates and/or
the ability to produce the flakes on larger extruders.
Pregelatinization is a process of precooking the starch using drum
drying, extrusion, or other methods. Thus, in an embodiment, binder
104 may be pregelatinized and provided in that form when blended
with the whole grain particulate.
[0024] In an embodiment, at the blending stage or when fed into the
extruder, other ingredients (110) may be included, such as nuts,
sugar/sweetener, salt, flavorings, etc. In an embodiment, the other
ingredients 110 may comprise a liquid syrup blend of
sugar/sweetener, honey, salt, and/or flavoring, etc. In an
embodiment, the particulate portion of the blend should be 15%-70%,
such as 40-60% or more, such as greater than 50%, on a dry weight
basis of the resultant extrudate, in order to provide the desired
look of the finished flakes. In an embodiment, the particulate or
mixture thereof selected may impact the characteristics of the
finished flake, and thus may drive the percentage of particulate
utilized. For example, some particulates, such as wheat, tend to
break into smaller pieces during the flaking process and thus may
be used at higher levels to achieve the desired characteristics,
whereas some other particulates, such as oats, retain substantial
integrity through the flaking process and thus may be used at lower
levels while still achieving the desired characteristics.
[0025] In an embodiment, the blend may be cooked in a low shear
extruder 108 to prevent degradation of the particulate. Further, in
an embodiment, a low degree of cook may be provided to the binder
(starch and protein) so that the resultant material has a high
viscosity necessary for binding the particulate and to provide a
texture crunchier than standard cereal flakes.
[0026] In an embodiment, the extrudate may be cut into pellets and
fed to flaking rolls 112 that are selected to flake the cereal to
0.030-0.080 inch thick flakes. In an embodiment, the flakes may be
produced with a greater than 0.030 inch thickness, for example
approximately 0.040-0.060 inch thick. In accordance with an
embodiment of the present invention, thicker flakes comprised of
suitable agreements may retain the granola appearance and add to
the crunchy texture. If made at this thickness, standard flakes of
corn, bran, oat, etc. would be hard and glassy, and thus, generally
possess an unpleasant texture. The ingredients and process
according to embodiments of the present invention, such as the
percentages of particulate and starch/protein, as well as the low
cook level, allow for the production of thicker flakes with
desirable texture. In an embodiment, even thicker flakes may be
produced using processes described herein, such as flakes greater
than 0.080 inch thick. In such situations, in an embodiment, it may
be useful to select binders that puff somewhat during the cooking
process to soften the harder texture resulting from the thicker
flakes.
[0027] In an embodiment, a flake may be formed that is
approximately 0.2 to 2.0 inches in diameter. While the flakes may
have a variety of shapes and may be regular or irregular in shape,
for the purposes of describing embodiments of the present
invention, the term "diameter" refers roughly to the long dimension
of the flake (whether or not the flake exhibits a round, square,
rectangular, or other profile) which gives a sense of relative size
of the flake.
[0028] In an embodiment, the resultant flakes may be toasted and
dried in a typical fluid bed dryer 114 at temperatures of
350-500.degree. F. for approximately 1 to 5 minutes. In an
embodiment, drying the flakes to moisture levels above 5% reduces
the desirability of preservatives or special packaging to preserve
freshness. In an alternative embodiment, flakes may be dried to
less than 5%, however, the use of preservatives and/or special
packaging may be beneficial in such a situation.
[0029] In an embodiment, dried flakes may be coated 116 with a
sugar/sweetener, flavoring, and/or oil to improve flavor, sweetness
and/or bowl life.
[0030] In an embodiment, whether coated or not, flakes may dried
118 to finished moisture for packaging.
[0031] In an embodiment, an exemplary dry feed formula may comprise
60-80% by weight, such as approximately 71%, oat groats (or other
whole grain source), 10-30% by weight, such as approximately 20%,
rice flour (or other binder), and 5-15% by weight, such as
approximately 9%, pecans (or other nuts).
[0032] In an embodiment, an exemplary final flake may comprise
40-60% by weight, such as approximately 49%, oat groats (or other
whole grain source), 10-20% by weight, such as approximately 14%,
rice flour (or other binder), and 1-10% by weight, such as
approximately 6%, pecans (or other nuts), 20-30% by weight, such as
approximately 24%, evaporated cane juice (or other sugar or
sweetener), approximately 3% honey or less, approximately 0.5%
vanilla flavoring or less, approximately 0.2% salt (such as sea
salt) or less, and approximately 2-6%, such as approximately 4%,
canola oil (or other oil).
[0033] Although certain embodiments have been illustrated and
described herein for purposes of description of the preferred
embodiment, it will be appreciated by those of ordinary skill in
the art that a wide variety of alternate and/or equivalent
embodiments or implementations calculated to achieve the same
purposes may be substituted for the embodiments shown and described
without departing from the scope of the present invention. Those
with skill in the art will readily appreciate that embodiments in
accordance with the present invention may be implemented in a very
wide variety of ways. This application is intended to cover any
adaptations or variations of the embodiments discussed herein.
Therefore, it is manifestly intended that embodiments in accordance
with the present invention be limited only by the claims and the
equivalents thereof.
* * * * *